72V ONYX Kelly Controller Parameters

Intro

This document captures the stock Kelly KLS7230S controller configuration used on the 72V ONYX. It preserves the exact factory parameter set exposed through the Kelly interface while documenting controller behavior that is not always visible in standard Kelly configuration tools.

The intent is to provide a reliable baseline for diagnostics, comparison, and controlled tuning without altering original data.

Summary

• Full stock parameter set preserved without modification
• Control loop fields clarified to reflect actual controller architecture
• Firmware-dependent parameters and hidden behavior documented
• System behavior explained without altering configuration
• Suitable as a baseline reference for tuning and validation

System Overview

Stock Kelly Controller Settings

Some parameters may not appear in all versions of the Kelly controller interface. Visibility can vary depending on firmware version, software (Motormed / AC Aduser), and controller configuration. Missing fields in the UI do not indicate missing functionality.

This table lists the factory configuration for the Kelly KLS7230S controller used on the 72V ONYX.

Additional Parameters (Firmware Dependent)

The Kelly KLS7230S controller may expose additional parameters depending on firmware version, controller revision, and configuration software. These are not present in this dataset but may appear in other controller variants.

Their absence in the table does not indicate missing functionality.

These parameters are often controlled internally by firmware, may not be visible or adjustable through standard Kelly configuration tools, and follow the same system relationships defined above. They may also override or interact with user-visible settings in the main configuration table.

Field Weakening

• Min Excitation
• Max Excitation
• Field Weakening Enable
• Flux Weakening %

Controls high-speed operation beyond base voltage limits.

• allows the motor to exceed its natural RPM limit at a given voltage
• works by reducing effective magnetic field strength
• increases speed at the cost of efficiency

Behavior characteristics:

• increases current draw at high RPM
• significantly increases motor heat
• reduces torque efficiency at speed
• effect becomes more noticeable near top speed

Important:

• field weakening does not increase power, only extends speed range
• excessive values can overheat the motor quickly
• behavior depends heavily on battery voltage and load

Regenerative Braking Control

• Max Regen Current
• Regen Current Limit
• EBS Level

Defines the actual current used during regenerative braking.

• acts as a ceiling independent of percentage-based braking
• limits how much energy is pushed back into the battery

Behavior characteristics:

• higher values increase braking force
• increases battery charging current during deceleration
• excessive values can stress battery or BMS

Important:

• may override or interact with BRK_SW / BRK_AD percentages
• actual regen behavior is a combination of percentage + current limits
• regenerative braking is strongest at higher speeds and weakens at low speed due to reduced back EMF

Torque and Speed Limits

• Torque Limit
• Max Torque Command
• Absolute Speed Limit

Defines hard constraints on controller output.

• torque limit caps maximum motor force
• speed limit caps maximum RPM independently of throttle

Behavior characteristics:

• limits apply regardless of throttle input
• can reduce peak performance even if other settings are high
• useful for protecting battery, motor, or drivetrain

Important:

• may override phase current or throttle mapping
• can create flat or limited acceleration if set too low

Voltage Compensation

• Bus Voltage Compensation
• Power Limit vs Voltage

Controls how the controller responds to voltage sag.

• adjusts output based on battery voltage under load
• helps stabilize performance as voltage drops

Behavior characteristics:

• can smooth power delivery under heavy load
• reduces performance drop from voltage sag
• may increase current draw to maintain output

Important:

• aggressive compensation increases battery stress
• interacts directly with battery current limits

Control Mode and Behavior Flags

• Torque Mode / Speed Mode selection
• Regen enable modes
• Direction change protection behavior

Defines internal controller operating modes and logic flags.

• selects how throttle input is interpreted (torque vs speed control)
• controls when and how regen is applied
• defines safety behavior for direction changes

Behavior characteristics:

• changes overall feel of throttle response
• affects how aggressively the controller reacts to inputs
• may alter stability and smoothness

Important:

• typically firmware-controlled
• not always user-configurable
• incorrect configuration can create unstable or unsafe behavior

Parameter Behavior and Relationships

These parameters do not operate independently. Most values interact within control systems, and behavior should be evaluated based on combined effects rather than individual fields.

Voltage and Protection Limits

• Controller Volt
• Low Volt
• Over Volt

Defines the operating voltage window of the controller.

• Controller Volt defines nominal system voltage used for internal scaling and protection calculations
• Low Volt controls cutoff behavior under battery sag
• Over Volt defines maximum allowable input before shutdown

Current and Power Control

• Current Percent
• Bat Current Limit
• Phase Curr Max AD
• Motor Normal Curr
• Motor Identity En

Defines how power is drawn from the battery and delivered to the motor.

• battery current controls total system power and battery stress
• phase current controls torque production
• motor current defines sustained operating limits

Motor Normal Curr is the controller’s continuous motor current reference and relates to sustained output behavior and protection thresholds.

Motor Identity En is associated with motor identification and calibration behavior used by the controller to align internal control with the connected motor.

Current and Power Tuning Reference

Behavior examples:

• Increasing Bat Current Limit (55 → 100)

  • increases total power output
  • increases battery sag and heat
  • directly impacts range and battery stress

• Increasing Phase Curr Max AD

  • increases launch torque significantly
  • improves acceleration without proportional battery load
  • increases motor heating under load

Throttle Input Mapping

• TPS Low
• TPS High
• TPS Type
• TPS Dead Low
• TPS Dead High
• TPS Forw MAP
• TPS Rev MAP
• Accel Time
• Accel Release Time

Defines how throttle input is interpreted and translated into torque demand.

• TPS range defines usable throttle span
• dead zones prevent unintended activation
• mapping values shape response curve
• acceleration timing values control how quickly requested power is applied and removed

Accel Time affects throttle ramp-in behavior.

Accel Release Time affects throttle ramp-out behavior.

Throttle Tuning Reference

Behavior examples:

• Lowering TPS Dead Low

  • increases sensitivity at initial throttle
  • can make low-speed control more abrupt

• Increasing TPS Forw MAP

  • delivers torque earlier in throttle travel
  • increases responsiveness

• Lowering Accel Time

  • makes throttle response feel sharper
  • can increase abruptness during launch

Speed Limiting System

• Max Output Fre
• Max Speed
• Max Forw Speed%
• Max Rev Speed%
• MidSpeed Forw Speed
• MidSpeed Rev Speed
• LowSpeed Forw Speed
• LowSpeed Rev Speed
• Three Speed
• PWM Frequency
• Motor Poles

Defines how speed is limited across operating modes.

• percentage limits scale maximum speed
• three-speed settings define mode behavior
• max speed defines absolute ceiling

Max Output Fre defines the maximum electrical frequency output to the motor and indirectly limits achievable motor speed based on pole count.

Actual motor RPM is determined by electrical frequency (Max Output Fre) and motor pole count, not just Max Speed.

PWM Frequency defines controller switching frequency and can affect smoothness, audible noise, and controller heat behavior.

Speed Limiting Tuning Reference

Braking and Regenerative Behavior

• BRK_SW Brk %
• BRK_AD Brk %
• RLS_TPS Brk Per%
• NTL Brk Per%
• Brake Type
• Brake Dead Low
• Brake Dead High
• Brake Time
• Brake Release Time
• Brake SW Level
• Change Dir Brk %
• IVT BRK Max
• IVT BRK Min
• Anti Theft Curr#

Defines how braking input is converted into regenerative or braking force.

• multiple inputs are blended internally
• timing values control ramp behavior
• dead zones define activation thresholds
• switch level settings define how digital brake input is interpreted

Change Dir Brk % defines braking applied during direction changes.

IVT BRK Max and IVT BRK Min appear to define internal braking limits or thresholds and may be firmware-dependent in behavior.

Anti Theft Curr# defines current behavior associated with anti-theft operation.

Regenerative Braking Tuning Reference

Behavior examples:

• Increasing BRK_SW Brk % (25 → 50)

  • increases regenerative braking force
  • reduces reliance on mechanical brakes
  • increases motor heat under repeated braking

• Increasing RLS_TPS Brk Per%

  • adds deceleration when releasing throttle
  • can reduce coasting behavior

• Lowering Brake Time

  • makes braking response engage faster
  • can feel more abrupt at low speed

Compensation and Stability Control

• Compensation Per%
• Torque Speed KP
• Torque Speed KI
• Speed Err Limit

Defines how the controller compensates for load changes and manages speed-related response.

Compensation Per% appears to control output compensation behavior under changing load or voltage conditions.

Torque Speed KP and Torque Speed KI define a separate speed-related control loop used to manage response under changing torque demand.

Speed Err Limit defines the allowable speed error used by the controller before corrective behavior becomes more aggressive.

These values affect how stable or forceful the controller feels under load but are typically best left near proven settings unless behavior problems are being diagnosed.

Control Loops (PID)

• IQ Kp
• IQ Ki
• IQ Kp (second field)
• IK Ki

Defines the controller’s internal feedback systems.

• inner loop regulates motor current (Iq / Id)
• outer loop controls torque demand and speed response

These values are typically pre-tuned and should not be adjusted unless instability is observed.

Improper tuning can cause oscillation, instability, or delayed response.

Control Loop Tuning Reference

Thermal Protection

• High Temp Cut C
• High Temp Resume
• Motor Temp Sensor

Defines thermal protection behavior.

• High Temp Cut C defines shutdown threshold
• High Temp Resume defines recovery threshold
• Motor Temp Sensor defines sensor type used for thermal monitoring

Behavior characteristics:

• once cut temperature is reached, controller output is reduced or disabled
• system will not resume full operation until temperature drops below resume threshold
• repeated thermal cycling reduces sustained performance
• thermal limits are often reached faster at sustained high speed than during short acceleration bursts

Important:

• thermal limits are the true continuous power constraint
• aggressive tuning will reach these limits faster
• cooling and airflow directly affect performance sustainability

Sensor Configuration

• Hall Galvan Rate
• Line Hall Zero
• Line Hall Amplitude
• Line Hall High Err
• Line Hall Low Err
• Resolver Start Angle
• Speed Sensor Type
• Resolver Poles
• Exchange Phase AB
• 0° Hall
• 60° Hall
• 120° Hall
• 180° Hall
• 240° Hall
• 300° Hall
• Forw A Rise Hall
• Forw A Fall Hall
• Rev A Rise Hall
• Rev A Fall Hall

Defines motor position sensing and commutation mapping.

These values align controller output with motor position and should not be modified without full system recalibration.

Mode and Switch Logic

• Startup H-Pedal
• Brake H-Pedal
• NTL H-Pedal
• Joystick
• Three Gear Switch
• Boost
• Foot Switch
• SW Level
• 0,HIM;1,KIM
• Cruise
• Anti Slip
• Change Dir

Defines how external inputs and controller mode flags interact with operating behavior.

These values are typically binary enable or disable states stored internally as mode flags or bitfields.

Behavior Overview

The controller operates using a dual-loop control structure:

• Inner loop regulates motor current (Iq / Id)
• Outer loop controls torque demand and speed response

Diagnostics

Firmware Limitations

The Kelly interface does not expose all internal parameters. These cannot be modified through standard Kelly configuration tools.

Common Misconfigurations

Incorrect parameter changes can create issues that appear as hardware faults.

Common patterns:

• Increasing battery current too aggressively

  • causes voltage sag, heat, and reduced battery lifespan

• Increasing phase current without thermal awareness

  • creates strong launch but rapid motor heating

• Excessive regenerative braking

  • increases motor heat
  • can create abrupt or unstable deceleration

• Excessive field weakening

  • increases top speed but causes rapid motor heating and efficiency loss

• Improper throttle dead zone settings

  • results in jerky or unpredictable throttle response

• Mismatched speed limits across modes

  • creates inconsistent riding behavior

• Over-adjusting PID values

  • can cause oscillation, instability, or sluggish response

Real-World Symptoms and Likely Causes

Safe Tuning Workflow

Follow a controlled process when modifying controller parameters:

1. Record all stock values before making changes
2. Change only one parameter at a time
3. Test under real riding conditions after each change
4. Monitor battery sag, motor temperature, and controller response
5. Avoid combining multiple aggressive settings simultaneously
6. Revert immediately if abnormal behavior occurs

Safe tuning depends on:

• understanding parameter relationships
• respecting thermal limits
• observing real-world behavior under load

Final Advice

This configuration should be treated as a stable baseline.

Use it for:

• Controller replacement validation
• Diagnostic comparison
• Controlled tuning adjustments

All values are preserved exactly as configured in the stock ONYX RCR system. No assumptions or inferred changes have been introduced.